U.S. patent application number 16/371940 was filed with the patent office on 2019-10-03 for container for transport and storage of food products.
The applicant listed for this patent is Zume, Inc.. Invention is credited to Rick Bontrager, Casper W. Chiang, Alexander John Garden.
Application Number | 20190300263 16/371940 |
Document ID | / |
Family ID | 68055297 |
Filed Date | 2019-10-03 |
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United States Patent
Application |
20190300263 |
Kind Code |
A1 |
Chiang; Casper W. ; et
al. |
October 3, 2019 |
CONTAINER FOR TRANSPORT AND STORAGE OF FOOD PRODUCTS
Abstract
Systems and methods for providing compostable food containers
which preserve the quality of a food product for an extended
duration of time, and which optionally allow for cooking of the
food product therein. In some implementations, the food containers
are sturdy, stackable, insulating, and require minimal or no manual
labor to assemble. In some implementations, the food container
includes a base and a cover which cooperate to form a closed
chamber for supporting, protecting, insulating and optionally
cooking a food product, such as a pizza. The base and cover may
each be formed of a single layer of material including, but not
limited to, molded sugarcane fiber ("bagasse"), molded wood fiber,
molded bamboo fiber, molded paper or plastic.
Inventors: |
Chiang; Casper W.;
(Danville, CA) ; Garden; Alexander John; (Tiburon,
CA) ; Bontrager; Rick; (Mountain View, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Zume, Inc. |
Mountain View |
CA |
US |
|
|
Family ID: |
68055297 |
Appl. No.: |
16/371940 |
Filed: |
April 1, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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62651633 |
Apr 2, 2018 |
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62667179 |
May 4, 2018 |
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62697029 |
Jul 12, 2018 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 65/466 20130101;
B65D 81/3813 20130101; B65D 2543/00092 20130101; B65D 2581/3406
20130101; B65D 2585/366 20130101; B65D 81/343 20130101; B65D 81/261
20130101; B65D 43/022 20130101; Y02W 90/10 20150501; B65D 21/0223
20130101; B65D 25/14 20130101 |
International
Class: |
B65D 81/26 20060101
B65D081/26; B65D 21/02 20060101 B65D021/02; B65D 81/38 20060101
B65D081/38; B65D 81/34 20060101 B65D081/34; B65D 25/14 20060101
B65D025/14 |
Claims
1. A food container comprising: a compostable fiber base including
an upwardly facing food receiving portion that receives a food
product, the food receiving portion having an inner surface, a
plurality of radial channels running radially in the inner surface,
and a corresponding plurality of sector portions of the food
receiving portion delineated by the plurality of radial channels;
and a compostable fiber cover selectively engageable with the base,
the cover including a substantially downward facing interior
surface and a substantially upward facing exterior surface, the
cover sized and shaped to provide an interior chamber which
protects the food product, the cover including a peripheral
sidewall having an inner surface, a smooth portion of the inner
surface, and a rough portion of the inner surface.
2. The food container of claim 1 wherein the smooth portion and the
rough portion of the inner surface promote increased condensation
of vapor within the interior chamber and direct condensed liquid
into specific regions of the food container.
3. The food container of claim 1 wherein the smooth portion of the
inner surface is located above the rough portion of the inner
surface.
4. The food container of claim 1 wherein a material of the sidewall
is porous.
5. The food container of claim 1 wherein a material of the sidewall
is capable of absorbing or adsorbing liquid.
6. The food container of claim 1 wherein the smooth portion of the
inner surface of the sidewall is sloped so that water condensed
onto the smooth portion of the inner surface of the sidewall flows
down the sidewall.
7. The food container of claim 1 wherein the smooth portion of the
inner surface of the sidewall is contiguous.
8. The food container of claim 1 wherein the smooth portion of the
inner surface of the sidewall is non-contiguous.
9. The food container of claim 8 wherein the smooth portion of the
inner surface of the sidewall is contiguous.
10. The food container of claim 1 wherein the smooth portion of the
inner surface of the sidewall is hydrophobic.
11. The food container of claim 1 wherein a material of the
sidewall is hydrophobic.
12. The food container of claim 1 wherein the smooth portion of the
inner surface is connected with one or more channels or recessed
areas for collecting condensed water.
13. The food container of claim 1, further comprising a coating
material applied to the smooth portion of the inner surface, the
coating material different than the compostable fiber material of
the cover.
14. The food container of claim 13, wherein the coating material is
hydrophobic.
15. The food container of claim 1, further comprising a laminating
material that is laminated to the smooth portion of the inner
surface, the laminating material different than the compostable
fiber material of the cover.
16. The food container of claim 15, wherein the laminating material
is hydrophobic.
17. The food container of claim 1 wherein each of the sector
portions of the food receiving portion includes a plurality of
circumferentially extending ribs that extend upward relative to
other portions of the food receiving portion.
18. The food container of claim 1 wherein the fiber cover has an
overall height of at least 2.5 inches.
19. The food container of claim 1 wherein the fiber base includes a
raised peripheral rim disposed about a perimeter of the food
receiving portion, the raised peripheral rim including a plurality
of cutting notches formed therein.
20. The food container of claim 19 wherein the raised peripheral
rim is thicker at locations below the cutting notches than at other
portions of the raised peripheral rim.
21. A method of forming a food container comprising: molding a
compostable fiber base including an upwardly facing food receiving
portion that receives a food product, the food receiving portion
having an inner surface, a plurality of radial channels running
radially in the inner surface, and a corresponding plurality of
sector portions of the food receiving portion delineated by the
plurality of radial channels; and molding a compostable fiber cover
selectively engageable with the base, the cover including a
substantially downward facing interior surface and a substantially
upward facing exterior surface, the cover sized and shaped to
provide an interior chamber which protects the food product, the
cover including a peripheral sidewall having an inner surface, a
smooth portion of the inner surface, and a rough portion of the
inner surface.
22. The method of claim 21 wherein the smooth portion of the inner
surface is molded against a polished metal surface and the rough
portion of the inner surface is molded against a mesh material.
23. The method of claim 21, further comprising: positioning a food
item on the food receiving portion of the fiber base; engaging the
fiber cover with the fiber base such that the food item is within
the interior chamber; and cooking the food item while on the food
receiving portion of the fiber base and within the interior
chamber.
24. The method of claim 23 wherein the cooking is performed in an
oven.
25. The method of claim 24 wherein the cooking is performed at a
temperature higher than 500 degrees Fahrenheit.
26. The method of claim 23 wherein the cooking is performed in a
commercial oven.
27. The method of claim 26 wherein the cooking is performed at a
temperature of at least 900 degrees Fahrenheit.
28. A molding system for molding a food container, the molding
system comprising: a first mold configured to mold a compostable
fiber base including an upwardly facing food receiving portion that
receives a food product, the food receiving portion having an inner
surface, a plurality of radial channels running radially in the
inner surface, and a corresponding plurality of sector portions of
the food receiving portion delineated by the plurality of radial
channels; and a second mold configured to mold a compostable fiber
cover selectively engageable with the base, the cover including a
substantially downward facing interior surface and a substantially
upward facing exterior surface, the cover sized and shaped to
provide an interior chamber which protects the food product, the
cover including a peripheral sidewall having an inner surface, a
smooth portion of the inner surface, and a rough portion of the
inner surface.
Description
TECHNICAL FIELD
[0001] The present disclosure generally relates to containers for
protecting, insulating, transporting and/or cooking food
products.
BACKGROUND
Description of the Related Art
[0002] Today, the standard pizza box is a square box that is made
from a single folded blank of corrugated cardboard. Once folded,
the cardboard forms a box that is normally about two inches high
and having equal sides of between 12 inches and 18 inches. The
corrugated cardboard used to produce the pizza box is typically
thick, which provides the pizza box with structural strength needed
to stack multiple filled pizza boxes atop one another without the
bottom box collapsing. Even then, stacking two or more pizza boxes
together typically requires the ubiquitous pedestals or "pizza
savers" which are placed within the box at the approximate center
thereof to prevent the top or lid of the pizza box from being
forced into contact with the pizza inside the box due to forces of
one or more pizza boxes stacked on top of the pizza box. An example
of such pizza saver is shown in U.S. Pat. No. 4,498,586.
[0003] In a traditional pizza box, the inside bottom surface of the
pizza box is flat and smooth. When a pizza is placed inside the
box, the bottom of the pizza rests flush against the flat bottom of
the box. Consequently, any condensation, grease, or other liquid
that collects between the bottom of the pizza and the bottom of the
box becomes trapped. This can cause the bottom of a pizza to become
soggy or oily, and can also reduce the structural integrity of the
pizza box. Additionally, the top of the pizza box absorbs moisture
emanating from hot, steaming pizza, which causes the top portion to
droop, and which may cause the pizza box to collapse or may at
least cause the top portion of the pizza box to touch the top of
the pizza in instances where the aforementioned "pizza saver" is
not used.
[0004] It is often desirable for baked food items to be hot and
have a crispy texture. An amount of time between the food being
cooked and being consumed by a consumer can affect the desirability
of the food, including its temperature and its crispiness. The
temperature of baked food items typically decreases over time, and
if the food item is stored in a closed environment to maintain the
temperature, then reabsorption of vapors tends to reduce the
crispiness and make the food soggy. This effect can be especially
pronounced for delivered foods, such as delivered pizza.
[0005] Traditionally, pizza is delivered in a roughly square and
flat corrugated cardboard box with a box support and a few cutout
holes to let vapor escape from the package. If the vapor does not
escape or is not vented from the box quickly, then the vapor is
either reabsorbed by the pizza, making the pizza soggier, or
absorbed by the box, making the box softer and weaker. If the vapor
does escape or is vented from the box quickly, however, then the
vapor can carry a significant amount of heat away from the pizza
and out of the box, reducing the temperature of the pizza.
BRIEF SUMMARY
[0006] A compostable fiber food container may be summarized as
including: a base including at least a portion of a raised rim
disposed about a perimeter of an upwardly facing food receiving
portion which receives a food product, the food receiving portion
including an inner surface and a plurality of wells disposed in the
food receiving portion that extend downwardly from the inner
surface and which project outwardly from a bottom face of the base
as a number of feet; and a compostable fiber cover selectively
engageable with the base, the cover including a central dome
portion having a substantially downward facing interior surface and
a substantially upward facing exterior surface, the interior
surface of the central dome portion having at least a portion of a
channel disposed about a perimeter of the central dome that are
sized and dimensioned to engage the at least a portion of the
raised rim of the base when the cover is engaged with the base, and
the central dome portion sized and shaped to provide an interior
chamber which protects the food product, and the exterior surface
of the central dome portion includes a plurality of dome recesses,
at least some of the plurality of dome recesses sized and
dimensioned to receive at least a portion of respective ones of the
feet of a base of another food container identical to the food
container when the other food container is stacked on top of the
cover of the food container.
[0007] The base may include a number N of wells, the cover may
include the number N of dome recesses, and each of the dome
recesses may be vertically aligned with one of the wells when the
cover is engaged with the base. The base may include eight wells
and the cover may include eight dome recesses, each of the dome
recesses may be vertically aligned with one of the wells when the
cover is engaged with the base. The central dome portion may
include a raised outer rim spaced radially outward from a center of
the central dome portion, and each of the dome recesses may be
disposed on the outer rim of the central dome portion. At least a
portion of each of the dome recesses may be disposed inward of an
apex of the outer rim. The central dome portion may include a
raised inner rim spaced radially outward from the center of the
dome portion and spaced radially inward from the raised outer rim.
Each well may have a rim adjacent the planar surface which may have
an oval profile. Each of the wells and each of the dome recesses
may be sized and dimensioned to restrict at least one of lateral
movement or rotational movement between the cover of the food
container and a base of another food container when the other food
container is stacked on the cover of the food container. The base
may include a plurality of sector portions, in which each sector
portion may include a plurality of raised sector ribs extending
upwardly from the planar surface. Each of a plurality of features
including the raised rim, the wells, the channels, and the raised
sector ribs may be spaced apart from at least one other of the
plurality of features by a distance which is less than or equal to
one inch. The base may have an overall height which is less than or
equal to 1.5 inches. Each of the base and the cover may be formed
from a single layer of material having a thickness in the range of
0.5 millimeters to 1.0 millimeters. The food receiving portion of
the base may not have a continuously planar surface which exceeds 2
inches by 2 inches. Each of the base and the cover may have a
length dimension which is greater than or equal to 12 inches. Each
of the base and the cover may be formed from one of sugarcane
fiber, wood fiber, or bamboo fiber. The base may have a square
perimeter with rounded edges, and the food receiving portion may
have a perimeter having a circular profile. The cover may have at
least one denesting lug which provides a space between at least a
portion of the cover and at least a portion of another cover when
the cover is stacked together with the other cover. The raised rim
of the base may include a plurality of cover interface portions
that extend radially outward from the remainder of the raised rim,
and the perimeter channel of the cover may be sized and dimensioned
to engage each of the plurality of cover interface portions of the
base when the cover is engaged with the base to provide an
interference fit between the cover and the base.
[0008] A food container may include: a base of molded compostable
fiber, the base including one or more protrusions disposed about a
perimeter of an upwardly facing food receiving portion which
receives a food product, the base having a bottom face, and the
food receiving portion including an inner surface with a plurality
of wells that project outwardly as respective mateable stacking
feet from the bottom face of the base; and a cover of molded
compostable fiber, the cover selectively engageable with the base,
the cover having a substantially downward facing interior surface
and a substantially upward facing exterior surface, the interior
surface of the cover having one or more depressions disposed about
a perimeter of the cover that are sized and dimensioned to engage
the at least a portion of the one or more protrusions of the base
when the cover is engaged with the base, and the cover sized and
shaped to provide an interior chamber which protects the food
product, and the exterior surface of the cover includes a plurality
of recesses, at least some of the plurality of recesses sized and
dimensioned to receive at least a portion of respective ones of the
mateable stacking feet of a base of another food container
identical to the food container when the other food container is
stacked on top of the cover of the food container.
[0009] The base may have a rectangular-shaped outer perimeter with
rounded corners, the outer perimeter defined by first and second
parallel edges and third and fourth parallel edges, and each of the
channels are non-parallel with each of the first, second, third,
and fourth edges of the base. The base may include a plurality of
sector portions in the food receiving portion, in which each sector
portion of the food receiving portion may include one of the
plurality of wells that extends downwardly from the planar surface.
Each well may have a rim adjacent the planar surface which has a
profile in the shape of at least one of an oval, a circle, a
triangle, a square, or a symbol. Each sector portion may include a
raised sector portion rim which extends upward from the planar
surface and is adjacent at least one of the two adjacent channels
which delineate the sector portion. At least some of the raised
sector ribs in each sector portion may have a length dimension
which extends radially with respect to the central well. The base
may include a base flange surrounding at least a portion of the
raised rim, and the cover may include a cover flange surrounding at
least a portion of the central dome portion. The base flange may
include at least one base fastening recess which extends downwardly
from the base flange, and the cover flange may include at least one
corresponding cover fastening protrusion which extends downwardly
from the cover flange, the at least one base fastening recess sized
and dimensioned to receive at least a portion of the at least one
cover fastening protrusion when the cover is engaged with the base.
The at least one base fastening recess and the at least one cover
fastening protrusion may each be sized and dimensioned to provide
an audible cue when the at least one base fastening recess is
separated from the cover fastening protrusion. The at least one
base fastening recess may have a depth that is greater than 5
millimeters and a diameter that is greater than 8 millimeters, and
the at least one cover fastening protrusion may have a depth which
is 1 millimeter less than the depth of the at least one base
fastening recess, and a diameter which is 1 millimeter greater than
the diameter of the at least one base fastening recess. The at
least one base fastening recess may include a plurality of recesses
each having an upward facing surface and a downward facing surface,
the downward facing surface of each of the plurality of base
fastening recesses sized and dimensioned to be weight-bearing when
the base is disposed on a planar support surface. The base flange
may include at least one base fastening protrusion which extends
upwardly from the base flange, and the cover flange may include at
least one corresponding cover fastening recess which extends
upwardly from the cover flange, the at least one cover fastening
recess sized and dimensioned to receive at least a portion of the
at least one base fastening protrusion when the cover is engaged
with the base. When the cover is engaged with the base, a perimeter
of the cover flange may be vertically aligned with a perimeter of
the base flange. The food container may include a number N of
channels which delineate a corresponding number N of sector
portions of the food receiving portion, where N is a positive
integer. Each of the base and the cover may be formed from a single
layer of material. Each of the base and the cover may be formed
from one of sugarcane fiber, wood fiber, or bamboo fiber. The food
receiving portion may have a circular profile. The base and the
cover may each be formed from a single layer of material, and the
base and the cover may be sized and dimensioned to be nestable with
other bases and covers, respectively. The plurality of channels may
be equally radially spaced to enable cutting of the food product
into equally sized pieces when a cutting tool moves along the
channels.
[0010] A food container may be summarized as including: a base
including one or more depressions disposed about a perimeter of an
upwardly facing food receiving portion which receives a food
product, the food receiving portion including an inner surface and
a plurality of wells disposed in the food receiving portion that
extend downwardly from the inner surface and that project outwardly
as respective feet from the bottom face of the base; and a cover
selectively engageable with the base, the cover having a
substantially downward facing interior surface and a substantially
upward facing exterior surface, the interior surface of the cover
having one or more protrusions disposed about a perimeter of the
cover that are sized and dimensioned to engage the at least a
portion of the one or more depressions of the base when the cover
is engaged with the base, and the cover sized and shaped to provide
an interior chamber which protects the food product, and the
exterior surface of the cover includes a plurality of recesses, at
least some of the plurality of recesses sized and dimensioned to
receive at least a portion of respective ones of the feet of a base
of another food container identical to the food container when the
other food container is stacked on top of the cover of the food
container.
[0011] A food container may be summarized as including: a base
including one of a raised rim or channel disposed about a perimeter
of an upwardly facing food receiving portion which receives a food
product, the food receiving portion including an inner surface and
a plurality of depressions disposed in the food receiving portion
that extend downwardly from the inner surface and that project
outwardly as respective mateable stacking feet from the bottom face
of the base; and a cover selectively engageable with the base, the
cover having a substantially downward facing interior surface and a
substantially upward facing exterior surface, the interior surface
of the cover having the other of the raised rim or channel disposed
about a perimeter of the cover that are sized and dimensioned to
engage the one of the raised rim or channel of the base when the
cover is engaged with the base, and the cover sized and shaped to
provide an interior chamber which protects the food product, and
the exterior surface of the cover includes a plurality of recesses,
at least some of the plurality of recesses sized and dimensioned to
receive at least a portion of respective ones of the mateable
stacking feet of a base of another food container identical to the
food container when the other food container is stacked on top of
the cover of the food container.
[0012] A food container may be summarized as comprising: a
compostable fiber base including an upwardly facing food receiving
portion that receives a food product, the food receiving portion
having an inner surface, a plurality of radial channels running
radially in the inner surface, and a corresponding plurality of
sector portions of the food receiving portion delineated by the
plurality of radial channels; and a compostable fiber cover
selectively engageable with the base, the cover including a
substantially downward facing interior surface and a substantially
upward facing exterior surface, the cover sized and shaped to
provide an interior chamber which protects the food product, the
cover including a peripheral sidewall having an inner surface, a
smooth portion of the inner surface, and a rough portion of the
inner surface.
[0013] The smooth portion and the rough portion of the inner
surface may promote increased condensation of vapor within the
interior chamber and direct condensed liquid into specific regions
of the food container. The smooth portion of the inner surface may
be located above the rough portion of the inner surface. A material
of the sidewall may be porous. A material of the sidewall may be
capable of absorbing or adsorbing liquid. The smooth portion of the
inner surface of the sidewall may be sloped so that water condensed
onto the smooth portion of the inner surface of the sidewall flows
down the sidewall. The smooth portion of the inner surface of the
sidewall may be contiguous and/or non-contiguous. The smooth
portion of the inner surface of the sidewall and/or a material of
the sidewall may be hydrophobic. The smooth portion of the inner
surface may be connected with one or more channels or recessed
areas for collecting condensed water. The container may further
comprise a coating material applied to the smooth portion of the
inner surface, the coating material different than the compostable
fiber material of the cover. The container may further comprise a
laminating material that laminated to the smooth portion of the
inner surface, the laminating material different than the
compostable fiber material of the cover. The coating material
and/or the laminating material may be hydrophobic.
[0014] Each of the sector portions of the food receiving portion
may include a plurality of circumferentially extending ribs that
extend upward relative to other portions of the food receiving
portion. The fiber cover may have an overall height of at least 2.5
inches. The fiber base may include a raised peripheral rim disposed
about a perimeter of the food receiving portion, the raised
peripheral rim including a plurality of cutting notches formed
therein. The raised peripheral rim may be thicker at locations
below the cutting notches than at other portions of the raised
peripheral rim.
[0015] A method of forming a food container may be summarized as
comprising: molding a compostable fiber base including an upwardly
facing food receiving portion that receives a food product, the
food receiving portion having an inner surface, a plurality of
radial channels running radially in the inner surface, and a
corresponding plurality of sector portions of the food receiving
portion delineated by the plurality of radial channels; and molding
a compostable fiber cover selectively engageable with the base, the
cover including a substantially downward facing interior surface
and a substantially upward facing exterior surface, the cover sized
and shaped to provide an interior chamber which protects the food
product, the cover including a peripheral sidewall having an inner
surface, a smooth portion of the inner surface, and a rough portion
of the inner surface.
[0016] The smooth portion of the inner surface may be molded
against a polished metal surface and the rough portion of the inner
surface may be molded against a mesh material. The method may
further comprise: positioning a food item on the food receiving
portion of the fiber base; engaging the fiber cover with the fiber
base such that the food item is within the interior chamber; and
cooking the food item while on the food receiving portion of the
fiber base and within the interior chamber. The cooking may
performed in an oven, such as at a temperature higher than 500
degrees Fahrenheit, or in a commercial oven, such as at a
temperature of at least 900 degrees Fahrenheit.
[0017] A molding system for molding a food container may be
summarized as comprising: a first mold configured to mold a
compostable fiber base including an upwardly facing food receiving
portion that receives a food product, the food receiving portion
having an inner surface, a plurality of radial channels running
radially in the inner surface, and a corresponding plurality of
sector portions of the food receiving portion delineated by the
plurality of radial channels; and a second mold configured to mold
a compostable fiber cover selectively engageable with the base, the
cover including a substantially downward facing interior surface
and a substantially upward facing exterior surface, the cover sized
and shaped to provide an interior chamber which protects the food
product, the cover including a peripheral sidewall having an inner
surface, a smooth portion of the inner surface, and a rough portion
of the inner surface.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0018] In the drawings, identical reference numbers identify
similar elements or acts. The sizes and relative positions of
elements in the drawings are not necessarily drawn to scale. For
example, the shapes of various elements and angles are not
necessarily drawn to scale, and some of these elements may be
arbitrarily enlarged and positioned to improve drawing legibility.
Further, the particular shapes of the elements as drawn, are not
necessarily intended to convey any information regarding the actual
shape of the particular elements, and may have been solely selected
for ease of recognition in the drawings.
[0019] FIG. 1A is a top perspective view of a food container,
according to one illustrated implementation.
[0020] FIG. 1B is a top perspective view of the food container with
a cover of the food container separated from a base thereof,
according to one illustrated implementation.
[0021] FIG. 2A is a bottom perspective view of the food container,
according to one illustrated implementation.
[0022] FIG. 2B is a bottom perspective view of the food container
with the cover separated from the base, according to one
illustrated implementation.
[0023] FIG. 3 is a top plan view of the food container, according
to one illustrated implementation.
[0024] FIG. 4A is a sectional view of the food container taken
along the line 4A-4A of FIG. 3, according to one illustrated
implementation.
[0025] FIG. 4B is a sectional view of the food container taken
along the line 4A-4B of FIG. 1B, according to one illustrated
implementation.
[0026] FIG. 5A is a sectional view of the food container taken
along the line 5A-5A of FIG. 3, according to one illustrated
implementation.
[0027] FIG. 5B is a sectional view of the food container taken
along the line 5A-5B of FIG. 1B, according to one illustrated
implementation.
[0028] FIG. 6 is a bottom plan view of the cover of the food
container, according to one illustrated implementation.
[0029] FIG. 7 is a front elevational view of the cover of the food
container, according to one illustrated implementation.
[0030] FIG. 8 is a top plan view of the base of the food container,
according to one illustrated implementation.
[0031] FIG. 9 is a bottom plan view of the food container,
according to one illustrated implementation.
[0032] FIG. 10 is a front elevational view of the base of the food
container, according to one illustrated implementation.
[0033] FIG. 11A is a sectional elevational view of a first food
container vertically aligned with and spaced apart from a second
food container, according to one illustrated implementation.
[0034] FIG. 11B is a sectional elevational view of the first and
second food containers in a stacked relationship, according to one
illustrated implementation.
[0035] FIG. 11C is a detailed view of a portion of FIG. 11B,
according to one illustrated implementation.
[0036] FIG. 12 is a top plan view of a food container which
includes a number N of food receiving portion channels and a
corresponding number N of sector portions, according to one
illustrated implementation.
[0037] FIG. 13 is a sectional elevational view of the base of the
food container, showing various dimensions thereof, according to
one illustrated implementation.
[0038] FIG. 14A is a top perspective view of another food
container, according to one illustrated implementation.
[0039] FIG. 14B is a top perspective view of the food container of
FIG. 14A with a cover of the food container separated from a base
thereof, according to one illustrated implementation.
[0040] FIG. 15A is a bottom perspective view of the food container
of FIG. 14A, according to one illustrated implementation.
[0041] FIG. 15B is a bottom perspective view of the food container
of FIG. 14A with the cover separated from the base, according to
one illustrated implementation.
[0042] FIG. 16 is a top plan view of the food container of FIG.
14A, according to one illustrated implementation.
[0043] FIG. 17 is a bottom plan view of the cover of the food
container of FIG. 14A, according to one illustrated
implementation.
[0044] FIG. 18 is a front elevational view of the cover of the food
container of FIG. 14A, according to one illustrated
implementation.
[0045] FIG. 19 is a top plan view of the base of the food container
of FIG. 14A, according to one illustrated implementation.
[0046] FIG. 20 is a bottom plan view of the food container of FIG.
14A, according to one illustrated implementation.
[0047] FIG. 21 is a front elevational view of the base of the food
container of FIG. 14A, according to one illustrated
implementation.
[0048] FIG. 22A is a cross-sectional view of a profile of a cover
portion of a food container, according to at least one illustrated
implementation.
[0049] FIG. 22B is a cross-sectional view of a profile of a base
portion of a food container, according to at least one illustrated
implementation.
[0050] FIG. 23 is a cross-sectional view of a profile of another
cover portion of a food container, according to at least one
illustrated implementation.
[0051] FIG. 24 is a cross-sectional view of a profile of a cover
portion of a food container engaged with a base portion of the food
container, according to at least one illustrated
implementation.
[0052] FIG. 25 illustrates a rough surface of a food container,
according to at least one illustrated implementation.
[0053] FIG. 26 illustrates a smooth surface of a food container,
according to at least one illustrated implementation.
[0054] FIG. 27 is a top perspective view of a base portion of a
food container, according to at least one illustrated
implementation.
[0055] FIG. 28 is a bottom perspective view of the base portion of
FIG. 27, according to at least one illustrated implementation.
[0056] FIG. 29 is a top plan view of the base portion of FIG. 27,
according to at least one illustrated implementation.
[0057] FIG. 30 is a bottom plan view of the base portion of FIG.
27, according to at least one illustrated implementation.
[0058] FIG. 31 is a side elevational view of the base portion of
FIG. 27, according to at least one illustrated implementation.
[0059] FIG. 32 is a top perspective view of a cover portion of a
food container, according to at least one illustrated
implementation.
[0060] FIG. 33 is a bottom perspective view of the cover portion of
FIG. 32, according to at least one illustrated implementation.
[0061] FIG. 34 is a top plan view of the cover portion of FIG. 32,
according to at least one illustrated implementation.
[0062] FIG. 35 is a bottom plan view of the cover portion of FIG.
32, according to at least one illustrated implementation.
[0063] FIG. 36 is a side elevational view of the cover portion of
FIG. 32, according to at least one illustrated implementation.
[0064] FIG. 37 is a top perspective view of a food container
comprising the base portion of FIG. 27 and the cover portion of
FIG. 32, according to at least one illustrated implementation.
[0065] FIG. 38 is a bottom perspective view of the food container
of FIG. 37, according to at least one illustrated
implementation.
[0066] FIG. 39 is a top plan view of the food container of FIG. 37,
according to at least one illustrated implementation.
[0067] FIG. 40 is a bottom plan view of the food container of FIG.
37, according to at least one illustrated implementation.
[0068] FIG. 41 is a side elevational view of the food container of
FIG. 37, according to at least one illustrated implementation.
DETAILED DESCRIPTION
[0069] In the following description, certain specific details are
set forth in order to provide a thorough understanding of various
disclosed implementations. However, one skilled in the relevant art
will recognize that implementations may be practiced without one or
more of these specific details, or with other methods, components,
materials, etc. In other instances, well-known structures
associated with computer systems, server computers, and/or
communications networks have not been shown or described in detail
to avoid unnecessarily obscuring descriptions of the
implementations.
[0070] Unless the context requires otherwise, throughout the
specification and claims that follow, the word "comprising" is
synonymous with "including," and is inclusive or open-ended (i.e.,
does not exclude additional, unrecited elements or method
acts).
[0071] Reference throughout this specification to "one
implementation" or "an implementation" means that a particular
feature, structure or characteristic described in connection with
the implementation is included in at least one implementation.
Thus, the appearances of the phrases "in one implementation" or "in
an implementation" in various places throughout this specification
are not necessarily all referring to the same implementation.
Furthermore, the particular features, structures, or
characteristics may be combined in any suitable manner in one or
more implementations.
[0072] As used in this specification and the appended claims, the
singular forms "a," "an," and "the" include plural referents unless
the context clearly dictates otherwise. It should also be noted
that the term "or" is generally employed in its sense including
"and/or" unless the context clearly dictates otherwise.
[0073] The headings and Abstract of the Disclosure provided herein
are for convenience only and do not interpret the scope or meaning
of the implementations.
[0074] One or more implementations of the present disclosure are
directed to providing food containers which preserve the quality of
a food product for a duration of time, and which optionally allow
for cooking of the food product therein. In one or more
implementations, the food containers discussed herein are
structurally sturdy, stackable, thermally insulating, disposable
(e.g., compostable) and require minimal or no manual labor to
assemble. In some implementations, the food containers discussed
herein use a relatively small amount of material compared to
existing corrugated cardboard containers, which material is
compostable and/or recyclable.
[0075] Initially, a first implementations of a food container is
discussed with reference to FIGS. 1A-11C and 13. Then, a second
implementation of a food container is discussed with reference to
FIG. 12. Then, a third implementation of a food container is
discussed with reference to FIGS. 14A-21. Features of one or more
of the implementations discussed herein may be modified and/or
combined to provide further implementations.
[0076] Referring to FIG. 1A through FIG. 11C, various views of a
food container 100 are shown. The food container 100 is illustrated
as a container for containing a pizza for explanatory purposes, but
it should be appreciated that the present disclosure is not limited
to such. As shown in FIG. 1B, the food container 100 includes a
base 102 and a separate cover 104 which cooperate as shown in the
figures and described below to form a closed chamber 106 for
supporting, protecting, insulating and optionally cooking a food
product (e.g., pizza).
[0077] In some implementations, the base 102 and cover 104 may each
be separately formed of a single layer of liquid-resistant
insulating material including, but not limited to, molded sugarcane
fiber ("bagasse"), which is known to have heat resistance such that
it does not deform at temperatures of up to at least 450.degree. F.
and has a known ignition temperature above 500.degree. F., such as
of between 537.degree. F. and 681.degree. F., molded wood fiber,
molded bamboo fiber, molded paper, which has a known ignition
temperature of above 450.degree. F., such as 451.degree. F., or
plastic (e.g., biodegradable plastic, thermoplastic material,
bio-based plastic, recycled plastic, recyclable plastic). The base
and/or the cover may be opaque, semi-transparent, or transparent
(e.g., an opaque base made with molded fiber and a cover made with
transparent plastic material). This is in contrast to conventional
pizza boxes which are made from corrugated cardboard. In
implementations wherein the base 102 cover 104 are formed from
molded fibers, the single layer of material may have a relatively
small thickness of between 0.5 mm and 1.0 mm (e.g., 0.8 mm). In
implementations wherein the base 102 and cover 104 are formed from
plastic (e.g., polyethylene terephthalate (PET), polylactic acid
(PLA)), the single layer of material may have a thickness of
0.5-0.6 mm or less.
[0078] In some implementations, the base 102 is formed of a single
layer of insulating material and includes an upwardly facing
circular-shaped food receiving portion 108 which receives the pizza
thereon. The base 102 further includes a raised peripheral rim 110
disposed about a perimeter of the food receiving portion 108. The
rim 110 comprises a raised upwardly facing apex surface 112 (see
FIG. 4B) and an downwardly and outwardly extending sidewall 114
which meets with a substantially planar base flange 116 that
extends outwardly from the rim. As shown in FIG. 1B, the base
flange 116 has a substantially rectangular-shaped (e.g., square)
outer perimeter with rounded corners defined by first and second
parallel edges 118A and 118B and third and fourth parallel edges
118C and 118D. Among other things, the base flange 116 strengthens
the rigidity of the base 102.
[0079] The food receiving portion 108 of the base 102 includes a
planar surface 109 and a number of features which extend at least
one of upward or downward from the planar surface 109. In
particular, the food receiving portion 108 includes a central well
120 which extends downwardly from the planar surface 109 and
receives liquid drippings or condensation from the cooked food
(e.g., pizza) placed in the food container 100. In the illustrated
implementation, the central well 120 has a circular perimeter, but
may have other shapes (e.g., triangle, octagon) in other
implementations.
[0080] The food receiving portion 108 also includes a plurality of
food receiving portion channels or grooves 122 (also referred to
herein as "channels") extending downwardly below the planar surface
109 and running radially outward from the central well 120 and
terminating at the raised peripheral rim 110. In some
implementations, the radial channels 122 may extend only partially
between the central well 120 and the raised peripheral rim 110. In
the illustrated implementation, each of the channels 122 has a
U-shaped cross-sectional profile, but in other implementations the
channels may have other shapes (e.g., V-shaped). In some
implementations, each channel 122 may slope downward from the rim
110 toward the central well 120 to facilitate the flow of liquid
through the channel into the central well. Each pair of adjacent
channels 122 and a corresponding portion of the raised peripheral
rim 110 delineate a respective sector portion 124 of the food
receiving portion 108 which supports a portion of a food item
(e.g., an individual slice of pizza). In the illustrated
implementation, the base 102 includes eight channels 122 and eight
sector portions 124. Generally the base 102 may include N channels
and N sector portions, where N is a positive integer.
[0081] The plurality of channels 122 are equally radially spaced to
enable cutting of the food item (e.g., pizza) into equally sized
pieces when a cutting tool (e.g., knife) moves along the channels.
Since the channels 122 extended downward from the planar surface
109, a user may cut through the food item over the channels without
damaging (e.g., cutting) the food receiving portion 108 of the base
102. Further, each of the channels 122 are non-parallel with each
of the edges 118A-118D of the base 102, which improves the rigidity
of the base. In the illustrated implementation, each of the
channels 122 is offset by 22.5.degree. from perpendicular from a
respective one of the edges 118A-118D which the channel extends
toward. Further, each of the channels 122 is collinear with an
opposite channel that extends radially in the opposite direction.
Thus, when the base 104 is to be discarded (e.g., composted), the
user may fold the base along an axis which extends through two
opposing collinear channels to reduce the dimensions of the base so
the base will fit within a compost receptacle.
[0082] Among other things, the channels 122 function to strengthen
the base 102 in rigidity and provide supporting forces to the food
receiving portion 108 when the base is disposed on a resting
surface, such as a countertop, oven or another food container. The
channels 122 also serve as guides for a cutting tool to cut eight
equally sized pieces of a food item (e.g., pizza). Further, the
channels 122 provide air space below the food item, which provides
additional insulation. In some implementations, because the
channels 122 may be substantially covered by the food item placed
on the food receiving portion 108, indicia (e.g., visible and/or
tactile markings) may be positioned on or adjacent the rim 110
radially in line with the channels to aid the user in cutting the
pizza into pieces along the channels.
[0083] As discussed above, each pair of adjacent channels 122 and a
corresponding portion (e.g., a 45.degree. arc portion) of the
raised peripheral rim 110 delineate a respective sector portion 124
of the food receiving portion 108 which receives an individual
piece of the food item (e.g., slice of pizza). Each sector portion
124 includes a portion of the planar surface 109 and a raised
sector portion rim 126 (FIG. 1B) which extends upward from the
planar surface and adjacent each of the channels 122 which define
the sector portion. In addition to supporting the food item above
the planar surface 109, the raised sector portion rim 126 adjacent
the channels 122 may aid in supporting the food item near the
cutting location, thereby facilitating the cutting process to
provide accurate individual pieces.
[0084] Each sector portion 124 further includes a sector well 128
which may receive liquid drippings from the food product therein.
In the illustrated implementation, each sector well has a perimeter
rim adjacent the planar surface 109 which has an oval profile. In
other implementations, each of the perimeter rims may have a
profile in the shape of at least one of a circle, a triangle, a
square, another shape, or a symbol (e.g., logo). Each sector
portion 124 also includes a plurality of raised sector ribs or
projections 130 which extend upward from the planar surface 109
around the sector well 128 having an uppermost portion which
supports the hot food product (e.g., pizza). In some
implementations, the combined area of the ribs 130 in a sector
portion 124 is smaller than the portion of the planar surface 109
in the sector portion. Thus, when the food product is supported on
the uppermost portions of the ribs 130 and the raised sector
portion rim 126, heat loss due to conduction through the planar
surface 109 is substantially reduced compared to food containers
with flat bottom surfaces which have relatively large surface area
contact with the bottom surface of the food product. Additionally,
the raised ribs 130 and sector portion rim 126 tend to isolate the
bottom surface of the food product from the planar surface 109,
which prevents the food product from becoming soggy due to trapped
liquid on the planar surface 109 of the food receiving portion
108.
[0085] In the illustrated implementations, the shapes of the ribs
130 are elongated and have a length dimension which extends
radially with respect to the central well 120. Additionally, in the
illustrated implementations the ribs 130 are radially symmetrical.
In other implementations, the number, sizes and dimensions of the
raised ribs 130 may be different from shown in the figures. The
raised ribs 130 also function to improve the rigidity of the base
102.
[0086] In some implementations, each of a plurality of features of
the base 102 comprising the raised rim 110, the central well 120,
the sector wells 128, the channels 122, and the raised sector ribs
130 is spaced apart from at least one other of the plurality of
features by a distance which is less than or equal to one inch. In
some implementations, due to the aforementioned plurality of
features, the food receiving portion 108 of the base 102 does not
have a continuously planar surface which exceeds 2 inches by 2
inches. Such features significantly improve the strength of the
base 102, while allowing the base to have a length dimension
greater than 12 inches (e.g., 16 inches), a width dimension greater
than 12 inches (e.g., 16 inches), an overall height which is less
than 1.5 inches (e.g., 1 inch), and a material thickness between
0.5 mm and 1.0 mm (e.g., 0.8 mm). In other implementations, the
base 102 may have a relatively larger height and the cover 104 may
have a relatively smaller height.
[0087] The base flange 116 which extends around the raised rim 110
includes eight fastening recesses or seats 132 that extend
downwardly from the base flange. As discussed below, each of the
fastening recesses 132 of the base 102 receive a corresponding one
of a plurality of downwardly extending fastening protrusions 134 of
the cover 104 to selectively retain the cover on the base 102. The
fastening recesses 132 are generally dome-shaped in the illustrated
implementations, but may be other shapes and sizes in other
implementations. Further, other implementations may include more
fastening recesses, fewer fastening recesses, or no fastening
recesses.
[0088] In some implementations, at least some of the fastening
recesses 132, the central well 120, and the sector wells 128 extend
downwardly to a lowermost portion of the base 102 so that they are
weight-bearing and function as "feet" which form an insulating air
space below the food receiving portion 108 of the base 102 and a
resting surface when the base is supported on the resting surface.
Thus, the raised ribs 130 of each sector portion, together with at
least some of the fastening recesses 132, the central well 120, and
the sector wells 128, form a layer of air insulation between the
planar surface 109 of the food receiving portion 108 and the food
product and a layer of air insulation between the food receiving
portion and a resting surface using only a single layer of material
(i.e., the material which forms the base 102). Additionally, the
aforementioned "feet" raise the remainder of the base 102 (and
cover 104 when engaged with the base) slightly above a resting
surface (e.g., table), which causes a shadow to be cast, similar to
a more formal serving plate.
[0089] The cover 104 comprises a single layer of thermally
insulating material (e.g., molded fiber) and includes a central
dome portion 136 comprising a substantially downward facing
interior surface 138 (FIG. 2B) and a substantially upward facing
exterior surface 140 (FIG. 1B). As shown in FIG. 4B, the dome
portion 136 comprises a raised outer rim 142 spaced radially
outward from the center of the dome portion which terminates in a
downwardly and outwardly extending sidewall 144. The sidewall 144
meets with a substantially planar cover flange 146 which extends
laterally outwardly therefrom. Similar to the base flange 116, the
cover flange 146 has a substantially rectangular-shaped outer
perimeter with rounded corners defined by first and second parallel
edges 148A and 148B and third and fourth parallel edges 148C and
148D (see FIG. 1B). Among other things, the cover flange 146
strengthens the rigidity of the cover 104.
[0090] The cover flange 146 also includes eight integrally formed
fastening protrusions 134 which extend downwardly from the cover
flange. The fastening protrusions 134 are generally dome-shaped in
the illustrated implementations, but may be other shapes and sizes
in other implementations. Further, other implementations may
include more fastening protrusions, fewer fastening protrusions, or
no fastening protrusions. As shown in FIG. 11C, each of the
fastening protrusions 134 of the cover flange 146 is vertically
aligned with one of the integrally formed fastening recesses 132 of
the base flange 116 to form a fastener 131. In operation, each
fastening recess 132 may receive a corresponding fastening
protrusion 134 when the cover 104 is placed on the base 102. Among
other things, such fasteners 131 may restrict lateral or rotational
movement of the cover 104 relative to the base 102 which maintains
the alignment of the cover relative to the base. In some
implementations, each fastening recess 132 may be sized and
dimensioned to receive a corresponding fastening protrusion 134
responsive to an external force pushing the fastening recess and
the fastening protrusion together when the cover 104 is placed on
the base 102, forming an interference or press fit. In such
implementations, upon receiving a fastening protrusion 134, a
fastening recess 132 may generate a fastening force which
facilitates holding the cover 104 in a closed configuration on the
base 102. Such fastening force resists external forces applied to
the container 100 so that the container remains closed throughout
storage, transportation or any other function of the container.
[0091] In some implementations, the base flange 116 may include a
number of fastening protrusions that extend upwardly from the base
flange, and the cover flange 146 may include a corresponding number
of fastening recesses that extend upwardly from the cover flange.
In such implementations, the fastening recesses of the cover 104
may receive the fastening protrusions of the base 102.
[0092] For a plastic blister or thermoform package, due to its
elastic property, when a fastening or positioning mechanism is
separated the mechanism will generate an audio cue (e.g., "snap")
to signal the movement. This is due to the "undercut" design, which
is a commonly known design technique in the plastic packaging
industry. Such is feasible because the plastic molding process
allows the undercut design. For paper or molded pulp products, it
may not be possible make such an undercut design, and therefore it
is typically accepted that a molded pulp package cannot have any
locking design with an audible snap function. However, in some
implementations of the present disclosure, due to the combination
of dimension of the interference, the angle, and the thickness of
the base 102 and cover 104, the fastening mechanisms provide an
unexpected performance with an audible cue (e.g., "snap") when the
fastening protrusions are disengaged from the corresponding
fastening recesses. In some implementations, this audible cue may
be produced more than once (e.g., each time a fastening protrusion
is disengaged from a fastening recess). In some implementations,
each of the fastening recesses has a depth that is greater than 5
millimeters and a diameter that is greater than 8 millimeters, and
each of the fastening protrusions has a depth which is 1 millimeter
less than the depth of the fastening recesses, and a diameter which
is 1 millimeter greater than the diameter of the fastening
recesses.
[0093] The dome portion 136 further comprises an irregularly-shaped
raised inner rim 150 disposed radially inward of the raised outer
rim 142, and a substantially planar ceiling portion 152 disposed
inward of the raised inner rim. In some implementations, the raised
inner rim 150 has a radially asymmetric profile. A downwardly
extending dome portion channel or groove 154 is positioned radially
between the raised outer rim 142 and the raised inner rim 150. The
shapes and dimensions of the raised outer rim 142, the dome portion
channel 154 and the raised inner rim 150 may be different in other
implementations. The raised outer rim 142, the dome portion channel
154 and the raised inner rim 150 together provide rigidity to the
dome portion 136 which, as discussed below, provides support to the
ceiling portion 152 and facilitates stacking of multiple containers
100 together. In the illustrated example, the raised inner rim 150
is lower in height than the raised outer rim 142, but in other
implementations the height of the inner rim may be equal to or
greater than the outer rim. As discussed further below with
reference to FIGS. 11A-11C, the outer rim 142 of the central dome
portion 136 also includes eight spaced apart dome recesses 156 each
sized and dimensioned to receive at least a portion of a
corresponding sector well 128 of a base 102 of another food
container 100 when the other food container is stacked on top of
the cover 104 of the food container.
[0094] Among other things, the shapes of the sidewall 144, raised
outer rim 142, dome portion channel 154, and raised inner rim 150
function to improve the rigidity of the cover 104, and serve to
distribute supporting forces when an object (e.g., one or more
other food containers) is stacked on the cover 104. Further, the
shape of the interior surface 138 of the central dome portion 136
and/or the texture (e.g., rough texture) of the interior surface
may tend to absorb or retain moisture (e.g., condensation) which
reduces the amount of moisture that returns to the hot food item
(e.g., pizza) which could cause quality deterioration of the food
item. Additionally, the generally round shape of the central dome
portion 136 which corresponds to a round food item (e.g., pizza)
provides a reduced surface area for heat transfer compared to a
conventional square pizza box, thus prolonging the duration that
the food item maintains an elevated temperature. In other
implementations, the central dome portion 136 may be sized and/or
dimensioned differently than shown in the illustrated
implementations.
[0095] As shown in FIGS. 4A and 4B, the interior surface 138 of the
sidewall 144 of the central dome portion 136 has an inwardly and
downwardly facing perimeter channel 160 sized and dimensioned to
form engage the raised perimeter rim 110 of the base 102 when the
cover 104 is engaged with the base. When the cover 104 is engaged
with the base 102, the perimeter channel 160 of the sidewall 144 of
the cover contacts the top surface 112 and sidewall 114 of the
raised rim 110 of the base 102 to form a "seal" which may limit or
even prevent the flow of air into or out of the enclosed chamber
106 which houses the food item. In some implementations, the
perimeter channel 160 and the raised rim 110 are sized and
dimension to form an interference or press fit therebetween when
the cover 104 is engaged with the base 102.
[0096] The various features of the dome portion 136 provide
significant strength which, among other things, allows for stacking
multiple food containers 100 together. Specifically, the dome
portion 136 includes several curved or cornered portions which
together improve the rigidity of the cover 104. For example, the
dome portion 136 includes the perimeter channel 160 adjacent the
base flange 116, the curved sidewall 144 radially inward of the
perimeter channel, the raised outer rim 142 radially inward of the
sidewall, the dome portion channel 154 radially inward of the
raised outer rim, the raised inner rim 150 radially inward of the
dome portion channel, and the planar ceiling portion 152 radially
inward of the raised inner rim.
[0097] When the cover 104 is engaged with the base 102 (FIG. 4A),
the base flange 116 and cover flange 146 are also in contact and
fastened by the fasteners 131 which, as noted above, serve to
restrict lateral or rotational motion between the cover and the
base, to add strength to the assembled food container 100, and to
increase the limiting of airflow into the chamber 106. As discussed
above, in some implementations the fasteners 131 may form an
interference or press fit between each pair of protrusions 134 and
recesses 132 of the cover 104 and base 102, respectively. In such
implementations, the fasteners 131 also function to retain the
cover 104 on the base 102.
[0098] In the illustrated implementation, the outer dimensions of
the base 102 and the cover 104 are substantially matched which aids
the user in aligning the cover 104 when placing the cover onto the
base during use, particularly when the cover is not joined to the
base via a hinge (e.g., flexible joint). In some implementations,
due to various symmetries of the base 102 and the cover 104, the
cover may be secured to the base at any of four relative rotational
angles (e.g., 0.degree., 90.degree., 180.degree., and 270.degree.)
relative to the base. That is, the edge 148A (FIG. 1B) of the cover
104 may be vertically aligned with any of the edges 118A-118D of
the base 102. To remove the cover 104 from the base 102, the user
may lift the cover relative to the base with sufficient force to
overcome the "seal" between the perimeter channel 160 of the cover
and the rim 110 of the base and, in implementations where the
fasteners 131 are secured by interference or press fits, sufficient
force to overcome the fastening forces of the respective fasteners
131.
[0099] As shown in FIG. 1B, in some implementations, the raised rim
110 of the base 102 includes one or more grooves or notches 162 at
an intersection of the top surface 112 and the sidewall 114 of the
rim 110. Such grooves 162 may function to release the seal between
the cover 104 and the base 102 when the user begins to lift the
cover from the base prior to the perimeter channel 160 disengaging
with the remainder of the raised rim 110. Such feature
advantageously makes the cover 104 easier to remove from the base
102 when a user desires to access the food item in the food
container 100.
[0100] The base 102 and cover 104 of the food container 100 may be
nestable with other bases and covers, respectively, with a minimum
amount of vertical height (i.e., essentially the thickness of the
material for each component). That is, when a first base 102 is
stacked on top of a second base, the top surfaces of the features
of the lower second base are positioned adjacent the bottom
surfaces of corresponding features of the upper first base, with
minimal air space therebetween. Similarly, when a first cover 104
is stacked on top of a second cover, the top surfaces of the
features of the lower second cover are positioned adjacent the
bottom surfaces of corresponding features of the upper first cover.
Thus, numerous bases may be stacked together at a height which is
much less than the combined height of the individual bases.
Similarly, numerous covers may be stacked together at a height
which is much less than the combined height of the individual
covers. Such nesting feature is advantageous for shipping and for
storing the food containers 100 in a small space (e.g., restaurant,
vehicle, packaging).
[0101] Further, unlike conventional pizza boxes formed from a
cardboard blank which has to be folded, no pre-assembly is
required. Thus, the base 102 and cover 104 need not be handled by a
user until selected for use to perform its intended function, which
significantly reduces the likelihood of contamination.
[0102] In operation, a user may select a base 102 from a stack of
nested bases, place a food item (cooked or uncooked) onto the food
receiving portion 108 of the base, select a cover 104 from a stack
of nested covers, and lower the cover onto the base as shown in
FIGS. 1A and 2A.
[0103] Because the food item is generally supported above the
planar surface 109 of the food receiving portion 108 by the raised
ribs 130 and sector portion rim 126 of each sector portion 124,
liquid drippings from the food item fall away from the food item
and into the sector wells 128, the central well 120 and/or the
channels 122. Such features prevent the bottom of the food item
from becoming soggy in addition to strengthening the rigidity of
the food container. Thus, the aforementioned features of the food
container 100 provide a housing which is lightweight, sturdy,
compostable, and supports the food item in a manner which keeps the
food item in a hot and dry condition, which preserves the freshness
of the food item.
[0104] FIGS. 11A-11C show how the food container 100 is stackable
with one or more other food containers, such as another food
container 200 which is substantially the same or identical to the
food container 100. As shown in FIG. 11C, an inward facing portion
of the apex of the raised outer rim 142 of the central dome portion
136 of the cover 104 includes a plurality of dome recesses or seats
156 radially spaced from the center of the dome portion. Each of
the dome recesses 156 are sized and dimensioned to receive at least
a portion of one sector well 128 of a base 102 of another food
container 100 when the other food container is stacked on top of
the cover 104 of the food container 200. In some implementations,
the shape of the recesses 156 may complement the shape of the
sector wells 158 to maximize the contact surface area between the
recesses and the sector wells. Thus, the sector wells 128 function
as "feet" for the base of the food container 100 when the food
container 100 is stacked on top of the food container 200. When in
such a stacked relationship, only the sector wells 128 of the base
102 of the top food container 100 contact the dome recesses 156 of
the cover 104 of the bottom food container 200, which provides a
substantial air space between the two containers 100 and 200, thus
minimizing heat transfer therebetween. Additionally, since the
sector wells 128 of the base 102 of the top food container 100 are
spaced apart from the food product in the food container 100 and
the sector recesses 156 of the dome portion 136 of the bottom food
container 200 are not in contact with the food product in the food
container 200, surfaces of the food containers adjacent the hot
food products do not contact each other when the containers are
stacked, which further minimizes heat transfer between
containers.
[0105] As discussed above, the outer rim 142 of the central dome
portion 136 is structurally rigid and serves to distribute
supporting forces of the sector wells 128 of the base 102 when the
top food container 100 is stacked on the cover 104 of the bottom
food container 200. Moreover, when the food container 100 is
stacked on the food container 200 and the bottom surface of each of
the sector wells 128 of the base 102 is received in a respective
one of the dome recesses 156, the food container 100 and the food
container 200 are restricted from lateral or rotational movement
with respect to each other, which helps keep the food containers in
a stacked relationship during transportation of the food
containers.
[0106] FIG. 12 shows a simplified schematic diagram of a base 240
for a food container. The base 240 may be similar or identical to
the base 102 discussed above. In this implementation, the base 240
includes a food receiving portion 242 which includes a number N of
channels CC.sub.1-N which delineate a corresponding number N of
sector portions SP.sub.1-N. The channels CC.sub.1-N and sector
portions SP.sub.1-N may be similar to the channels 122 and sector
portions 124, respectively, discussed above. As a non-limiting
example, the number N may be equal to a positive integer (e.g., 4,
7, 8, 9, 10, 13, 16).
[0107] FIG. 13 shows a sectional elevational view of the base 102
and includes a number of dimensional measurements and radius of
curvature measurements in millimeters for the base 102, according
to one or more implementations. FIG. 6 also shows example
measurements for the outer edges of the cover 104 and/or base 102.
As shown, in some implementations the base 102 and cover 104 may
each have outer dimensions of 410 millimeters by 410 millimeters.
The aforementioned strengthening structural features allow the food
container 100 to be relatively large and to utilize a relatively
thin layer of material for each of the base and the cover while
providing the aforementioned required support for receiving a food
item and/or stacking multiple food containers together. Such
measurements are provided as examples and should not be considered
to be limiting.
[0108] Referring now to FIG. 14A through FIG. 21, various views of
a food container 300 are shown. The food container 300 may be
similar or identical to the food containers 100 and 200 in many
respects (e.g., shapes, materials, sizes, features). Accordingly,
at least some of the discussion above is applicable to the food
container 300 and may not be repeated below for the sake of
brevity.
[0109] As shown in FIG. 14B, the food container 300 includes a base
302 and a separate cover 304 which cooperate as shown in the
figures and described below to form a closed chamber for
supporting, protecting, insulating and optionally cooking a food
product (e.g., pizza). In at least some implementations, the base
302 is formed of a single layer of insulating material and includes
an upwardly facing circular-shaped food receiving portion 308 which
receives the pizza thereon. The base 302 further includes a raised
peripheral rim 310 disposed about a perimeter of the food receiving
portion 308. The rim 310 comprises a raised upwardly facing apex
surface 312 (FIG. 21) and a downwardly and outwardly extending
sidewall 314 which meets with a substantially planar base flange
316 that extends outwardly from the rim. As shown in FIG. 14B, the
base flange 316 has a substantially rectangular-shaped (e.g.,
square) outer perimeter with rounded corners defined by first and
second parallel edges 318A and 318B and third and fourth parallel
edges 318C and 318D. Among other things, the base flange 316
strengthens the rigidity of the base 302.
[0110] The food receiving portion 308 of the base 302 includes a
planar surface 309 and a number of features which extend at least
one of upward or downward from the planar surface 309. In
particular, the food receiving portion 308 includes a central well
320 which extends downwardly from the planar surface 309 and
receives liquid drippings or condensation from the cooked food
(e.g., pizza) placed in the food container 300. In the illustrated
implementation, the central well 320 has a circular perimeter, but
may have other shapes (e.g., triangle, octagon) in other
implementations.
[0111] The food receiving portion 308 also includes a plurality of
food receiving portion channels or grooves 322 (also referred to
herein as "channels") extending downwardly below the planar surface
309 and running radially outward from the central well 320 and
terminating at the raised peripheral rim 310. In some
implementations, the radial channels 322 may extend only partially
between the central well 320 and the raised peripheral rim 310. In
the illustrated implementation, each of the channels 322 has a
U-shaped cross-sectional profile, but in other implementations the
channels may have other shapes (e.g., V-shaped). In some
implementations, each channel 322 may slope downward from the rim
310 toward the central well 320 to facilitate the flow of liquid
through the channel into the central well. Each pair of adjacent
channels 322 and a corresponding portion of the raised peripheral
rim 310 delineate a respective sector portion 324 of the food
receiving portion 308 which supports a portion of a food item
(e.g., an individual slice of pizza). In the illustrated
implementation, the base 302 includes eight channels 322 and eight
sector portions 324. Generally the base 302 may include N channels
and N sector portions, where N is a positive integer.
[0112] The plurality of channels 322 are equally radially spaced to
enable cutting of the food item (e.g., pizza) into equally sized
pieces when a cutting tool (e.g., knife) moves along the channels.
Since the channels 322 extended downward from the planar surface
309, a user may cut through the food item over the channels without
damaging (e.g., cutting) the food receiving portion 308 of the base
302. Further, each of the channels 322 are non-parallel with each
of the edges 318A-318D of the base 302, which improves the rigidity
of the base. In the illustrated implementation, each of the
channels 322 is offset by 22.5.degree. from perpendicular from a
respective one of the edges 318A-318D which the channel extends
toward. Further, each of the channels 322 is collinear with an
opposite channel that extends radially in the opposite direction.
Thus, when the base 304 is to be discarded (e.g., composted), the
user may fold the base along an axis which extends through two
opposing collinear channels to reduce the dimensions of the base so
the base will fit within a compost receptacle.
[0113] Among other things, the channels 322 function to strengthen
the base 302 in rigidity and provide supporting forces to the food
receiving portion 308 when the base is disposed on a resting
surface, such as a countertop, oven or another food container. The
channels 322 also serve as guides for a cutting tool to cut eight
equally sized pieces of a food item (e.g., pizza). Further, the
channels 322 provide air space below the food item, which provides
additional insulation. In some implementations, because the
channels 322 may be substantially covered by the food item placed
on the food receiving portion 308, indicia (e.g., visible and/or
tactile markings) may be positioned on or adjacent the rim 310
radially in line with the channels to aid the user in cutting the
pizza into pieces along the channels.
[0114] As discussed above, each pair of adjacent channels 322 and a
corresponding portion (e.g., a 45.degree. arc portion) of the
raised peripheral rim 310 delineate a respective sector portion 324
of the food receiving portion 308 which receives an individual
piece of the food item (e.g., slice of pizza). Each sector portion
324 includes a portion of the planar surface 309 and a raised
sector portion rim 326 (FIG. 14B) which extends upward from the
planar surface and adjacent each of the channels 322 which define
the sector portion. In addition to supporting the food item above
the planar surface 309, the raised sector portion rim 326 adjacent
the channels 322 may aid in supporting the food item near the
cutting location, thereby facilitating the cutting process to
provide accurate individual pieces.
[0115] Each sector portion 324 further includes a sector well 328
which may receive liquid drippings from the food product therein.
In the illustrated implementation, each sector well has a perimeter
rim adjacent the planar surface 309 which has an oval profile. In
other implementations, each of the perimeter rims may have a
profile in the shape of at least one of a circle, a triangle, a
square, another shape, or a symbol (e.g., logo). Each sector
portion 324 also includes a plurality of raised sector ribs or
projections 330 which extend upward from the planar surface 309
around the sector well 328 having an uppermost portion which
supports the hot food product (e.g., pizza). In some
implementations, the combined area of the ribs 330 in a sector
portion 324 is smaller than the portion of the planar surface 309
in the sector portion. Thus, when the food product is supported on
the uppermost portions of the ribs 330 and the raised sector
portion rim 326, heat loss due to conduction through the planar
surface 309 is substantially reduced compared to food containers
with flat bottom surfaces which have relatively large surface area
contact with the bottom surface of the food product. Additionally,
the raised ribs 330 and sector portion rim 326 tend to isolate the
bottom surface of the food product from the planar surface 309,
which prevents the food product from becoming soggy due to trapped
liquid on the planar surface 309 of the food receiving portion
308.
[0116] In the illustrated implementations, the shapes of the ribs
330 are elongated and have a length dimension which extends
radially with respect to the central well 320. Additionally, in the
illustrated implementations the ribs 330 are radially symmetrical.
In other implementations, the number, sizes and dimensions of the
raised ribs 330 may be different from shown in the figures. The
raised ribs 330 also function to improve the rigidity of the base
302.
[0117] In some implementations, each of a plurality of features of
the base 302 comprising the raised rim 310, the central well 320,
the sector wells 328, the channels 322, and the raised sector ribs
330 is spaced apart from at least one other of the plurality of
features by a distance which is less than or equal to one inch. In
some implementations, due to the aforementioned plurality of
features, the food receiving portion 308 of the base 302 does not
have a continuously planar surface which exceeds 2 inches by 2
inches. Such features significantly improve the strength of the
base 302, while allowing the base to have a length dimension
greater than 12 inches (e.g., 16 inches), a width dimension greater
than 12 inches (e.g., 16 inches), an overall height which is less
than 1.5 inches (e.g., 1 inch), and a material thickness between
0.5 mm and 1.0 mm (e.g., 0.8 mm). In other implementations, the
base 302 may have a relatively larger height and the cover 304 may
have a relatively smaller height.
[0118] The outward facing sidewall 314 of the raised rim 310 of the
base 302 includes four cover interface portions 332 spaced
90.degree. apart from each other that extend radially outward from
the remainder of the outward facing sidewall 314. As discussed
further below, the cover interface portions 332 of the base 302
engage an inwardly and downwardly facing perimeter channel 360 of
the cover 304 when the cover is engaged with the base to provide a
friction fit between the cover and the base, which retains the
cover on the base until removed by a user.
[0119] In some implementations, at least some of the central well
320 and the sector wells 328 extend downwardly to a lowermost
portion of the base 302 so that they are weight-bearing and
function as "feet" which form an insulating air space below the
food receiving portion 308 of the base 302 and a resting surface
when the base is supported on the resting surface. Thus, the raised
ribs 330 of each sector portion, together with at least some of the
central well 320 and the sector wells 328, form a layer of air
insulation between the planar surface 309 of the food receiving
portion 308 and the food product and a layer of air insulation
between the food receiving portion and a resting surface using only
a single layer of material (i.e., the material which forms the base
302). Additionally, the aforementioned "feet" raise the remainder
of the base 302 (and cover 304 when engaged with the base) slightly
above a resting surface (e.g., table), which causes a shadow to be
cast, similar to a more formal serving plate.
[0120] The cover 304 comprises a single layer of thermally
insulating material (e.g., molded fiber) and includes a central
dome portion 336 comprising a substantially downward facing
interior surface 338 (FIG. 15B) and a substantially upward facing
exterior surface 340 (FIG. 14B). In at least some implementations,
the exterior surface 340 is circular in shape which facilitates
printing (e.g., laser printing, pad printing) thereon with text
and/or graphics (e.g., logo, image, instructions). As shown in FIG.
14B, the dome portion 336 comprises a raised outer rim 342 spaced
radially outward from the center of the dome portion which
terminates in a downwardly and outwardly extending sidewall 344.
The sidewall 344 meets with a cover flange 346 which extends
laterally outwardly therefrom. The cover flange 346 has a
substantially circular-shaped outer perimeter and includes tab
portion 348A that may align with one of the four corner portions of
the base flange 316 when the cover 304 is engaged with the base.
The tab portion 348A may be planar in shape or may have a distal
portion 348B that extends upward that may be grasped by the user to
remove the cover 304 from the base 302 during use. Among other
things, the cover flange 346 strengthens the rigidity of the cover
304.
[0121] The dome portion 336 further comprises a substantially
planar ceiling portion 352 disposed radially inward of the raised
outer rim 342. The raised outer rim 342 provides rigidity to the
dome portion 336 which, as discussed below, provides support to the
ceiling portion 352 and facilitates stacking of multiple containers
300 together. The outer rim 342 of the central dome portion 336
also includes eight spaced apart dome recesses 356 each sized and
dimensioned to receive at least a portion of a corresponding sector
well 328 of a base 302 of another food container 300 when the other
food container is stacked on top of the cover 304 of the food
container.
[0122] As noted above, the interior surface 338 of the sidewall 344
of the central dome portion 336 has the perimeter channel 360 sized
and dimensioned to engage the cover interface portions 332 of the
raised perimeter rim 310 of the base 302 when the cover 304 is
engaged with the base. In some implementations, the perimeter
channel 360 and the cover interface portions 332 of the raised rim
310 are sized and dimension to form a friction or interference fit
therebetween when the cover 304 is engaged with the base 302.
[0123] The various features of the dome portion 336 provide
significant strength which, among other things, allows for stacking
multiple food containers 300 together. Specifically, the dome
portion 336 includes several curved or cornered portions which
together improve the rigidity of the cover 304. For example, the
dome portion 336 includes the perimeter channel 360 adjacent the
base flange 316, the curved sidewall 344 radially inward of the
perimeter channel, the raised outer rim 342 radially inward of the
sidewall, and the planar ceiling portion 352 radially inward of the
raised inner rim.
[0124] As shown in FIG. 14B, in some implementations, the raised
rim 310 of the base 302 includes one or more grooves or notches 362
at an intersection of the top surface 312 and the sidewall 314 of
the rim 310. Such grooves 362 may function to release the seal
between the cover 304 and the base 302 when the user begins to lift
the cover from the base prior to the perimeter channel 360
disengaging with the cover interface portions 332 of the raised rim
310. Such feature advantageously makes the cover 304 easier to
remove from the base 302 when a user desires to access the food
item in the food container 300.
[0125] The base 302 and cover 304 of the food container 300 may be
nestable with other bases and covers, respectively, with a minimum
amount of vertical height (i.e., essentially the thickness of the
material for each component). That is, when a first base 302 is
stacked on top of a second base, the top surfaces of the features
of the lower second base are positioned adjacent the bottom
surfaces of corresponding features of the upper first base, with
minimal air space therebetween. Similarly, when a first cover 304
is stacked on top of a second cover, the top surfaces of the
features of the lower second cover are positioned adjacent the
bottom surfaces of corresponding features of the upper first cover.
Thus, numerous bases may be stacked together at a height which is
much less than the combined height of the individual bases.
Similarly, numerous covers may be stacked together at a height
which is much less than the combined height of the individual
covers. Such nesting feature is advantageous for shipping and for
storing the food containers 300 in a small space (e.g., restaurant,
vehicle, packaging).
[0126] In at least some implementations, the cover 304 may include
one or more spaced apart denesting lugs 334 disposed on an inward
facing surface 350 of the dome portion 336 spaced radially inward
from the raised outer rim 342. The denesting lugs 334 may be spaced
apart from each other at uneven intervals around the circumference
of inward facing surface 350. The denesting lugs 334 operate to
make it easier for a user to separate the covers from one another
when stacked. Thus, for example, a manufacturer of the covers may
provide a number of the covers stacked together which may be easily
separated prior to use. In particular, the denesting lugs 334
provide spacing between two stacked covers 304, which allows for
ease in grasping only one of the covers by an individual or a
machine. The uneven spacing of the denesting lugs 334 may reduce
the likelihood that the denesting lugs of one cover will align with
and fit into the denesting lugs of another cover stacked the cover,
which would cause the denesting lugs to fail to provide the
intended spacing between the two covers.
[0127] FIGS. 22A, 22B, 23, and 24 illustrate cross-sectional
profiles of respective cover portions 400a, 400b, and 400c
(referred to herein collectively as cover portions 400) and base
portions 402a and 402c (referred to herein collectively as base
portions 402) of respective food containers. As illustrated in
FIGS. 22A, 23, and 24, the cover portions 400 can include a planar
cover flange 404, a perimeter channel 406, a sidewall 408, a raised
outer rim 410, a groove 412, a raised inner rim 414, and/or a
ceiling portion 416. Thus, the cover portions 400 have structures
similar to the other cover portions described herein, and can
include any of the features of the other cover portions described
herein to the extent they are not incompatible with the features
described herein for the cover portions 400. Further, the features
described herein for the cover portions 400 can be incorporated
into any of the other cover portions described herein to the extent
they are not incompatible with the features of such other cover
portions. As illustrated in FIGS. 22B and 24, the base portions 402
can include a planar base flange 418, a sidewall 420, a peripheral
rim 422, and/or an apex surface 424. Thus, the base portions 402
have structures similar to the other base portions described
herein, and can include any of the features of the other base
portions described herein to the extent they are not incompatible
with the features described herein for the base portions 402.
Further, the features described herein for the base portions 402
can be incorporated into any of the other base portions described
herein to the extent they are not incompatible with the features of
such other base portions.
[0128] Heat may be lost from a hot baked food item in at least four
different ways: conduction, radiation, convection due to
temperature differences between the food item and an ambient or
environmental temperature, and vapor loss, which may depend on the
water content and temperature of the food item. As one example, a
pizza is baked in an oven at a temperature higher than 500 degrees
Fahrenheit, with temperatures up to 900 degrees Fahrenheit being
common with commercial ovens. A temperature of the pizza as it
comes out of the oven is often well over 212 degrees Fahrenheit,
which is the boiling point of water, with temperatures up to 240
degrees Fahrenheit being common. The latent heat or heat of
vaporization for water is about 2230 joules per gram. A pizza of 1
Kg can lose 15 grams of water in 20 minutes in open air, 20 grams
of water when in a box. This weight loss is directly proportional
to the temperature decrease due to the loss of water vapor. It has
been found that, between the various heat loss mechanisms, the heat
loss due to water vapor loss, or the latent heat loss, is the main
pathway of temperature loss.
[0129] Therefore, the cover portions 400 and base portions 402 are
configured and designed to condense the water vapor on inside
surfaces of the food containers, thereby capturing heat released by
the water vapor as it condenses inside the package. Because the
heat of condensation is equal to the heat of vaporization, it is
expected that most of the heat lost when the water is vaporized can
be recaptured by re-condensing the water vapor inside the package.
This recaptured heat can be retained by the cover portions 400, by
the base portions 402, by air surrounding a food item within an
internal chamber 426 defined between the cover portions 400 and the
base portions 402, or by the food item itself. Retaining this heat
and thereby raising the temperature within the internal chamber 426
above the food item, can also reduce the amount of heat that is
lost to convection.
[0130] The food containers and components thereof described herein,
including the cover portions 400 and the base portions 402, can be
manufactured of molded compostable fibers. In a method of molding a
component of the food containers described herein, including the
cover portions 400 and base portions 402, a pulp suspension is
formed, comprising approximately 5% fiber suspension and 95% water.
The pulp suspension is then mashed between a polished metal surface
and a mesh material, which allows the water, but not the fibrous
material, to escape the mold as the suspension is mashed, such as
under the application of a vacuum. As a result, one side surface of
a molded compostable component is typically very smooth and shiny
because it is molded against the polished metal surface, as
illustrated in one example in FIG. 26, while the opposing side
surface of the component is typically rough because it is molded
against the mesh, as illustrated in one example in FIG. 25.
[0131] The term "smooth" can be used to mean that a surface has a
smoothness or a roughness typical of surfaces of molded compostable
fiber materials when molded against a polished metal surface. Such
a smoothness or a roughness can be defined by elevation differences
between peaks and valleys of the surface, such as measured in a
direction perpendicular to the surface, of less than 0.05 mm, or
less than 0.02 mm, or less than 0.01 mm, or less than 0.005 mm. The
term "rough" can be used to mean that a surface has a smoothness or
a roughness typical of surfaces of molded compostable fiber
materials when molded against a wire mesh, such as against a wire
mesh with a mesh size of about 18.times.18. Such a smoothness or a
roughness can be defined by elevation differences between peaks and
valleys of the surface, such as measured in a direction
perpendicular to the surface, of greater than 0.05 mm, or greater
than 0.1 mm, or greater than 0.2 mm, or greater than 0.5 mm.
[0132] Smoothness and roughness can also be defined by the degree
to which a smooth surface differs from a rough surface. For
example, a rough surface can have a roughness, as defined by
elevation differences between peaks and valleys of the surface,
such as measured in a direction perpendicular to the surface, that
is larger than, at least twice as large as, at least five times as
large as, or at least ten times as large as a roughness, as defined
by elevation differences between peaks and valleys of the surface,
such as measured in a direction perpendicular to the surface, of a
smooth surface. A transition area between a smooth surface and a
rough surface can be as small as about 1/8 of an inch or about 1/16
of an inch. For reasons of aesthetics, it is typical to make the
outside of the food container smooth and the inside of the food
container rough.
[0133] As illustrated in FIGS. 23 and 24, the inner surfaces of the
sidewalls 408 of the cover portions 400 include upper, smooth
sections 428, which can also be porous or non-porous, and lower,
rough sections 430. While FIGS. 23 and 24 illustrate these features
in cross-sectional views, it will be understood that the upper
smooth sections 428 and the lower, rough sections 430 extend
circumferentially around an entire inner surface of the sidewalls
408. In some cases, each upper, smooth section 428 extends from an
uppermost point of the inner surface of the sidewall 408, at the
raised outer rim 410, to approximately a midpoint of the inner
surface of the sidewall 408 between the uppermost point and a
lowermost point of the inner surface of the sidewall 408, at the
perimeter channel 406. In other cases, each upper, smooth section
428 extends from an upper point of the inner surface of the
sidewall below the uppermost point, such as at an elevation
approximating the height of the ceiling portion 416, to the
approximate midpoint of the inner surface of the sidewall 408. Each
lower, rough section 430 can extend from the bottom end of the
respective upper, smooth section 428 at the approximate midpoint of
the inner surface of the sidewall 408 to the lowermost point of the
inner surface of the sidewall 408.
[0134] The smooth surfaces 428 increase the rate at which water
vapor inside the food container condenses onto the inner surfaces
of the sidewalls 408, such as by allowing the water vapor to
condense onto the smooth surfaces 428 at a lower temperature and
lower surface tension than on the rough surfaces 430. This
increases the amount of heat released back into the overall system,
such as into the sidewall 408 or into the air within the chamber
426. Once water vapor condenses onto a smooth surface 428 of an
inner surface of a sidewall 408, the liquid water can coalesce and
flow downward along the inner surface of the sidewall 408 under the
influence of gravity until it meets an interface between the cover
portion 400 and the base portion 402, where the water can be
absorbed into the molded compostable fibers of the cover portion
400, such as the sidewall 408, or the base portion 402, or be
retained within crevices formed between the components. The
sidewall 408 can be sloped, nearly vertical, or vertical with
respect to gravity to promote such flow. Because the water is
absorbed into the components of the food container, the water is
not absorbed by the food item stored within the food container, and
therefore does not impact the crispiness of the food item.
[0135] Smooth surfaces of molded compostable fibrous packaging
materials can also be shiny. Thus, the smooth surfaces 428 formed
on the inner surface of the cover portions 400 can also reduce heat
losses by reflecting heat that otherwise would have been lost by
convection, conduction, and/or radiation. In some cases, a food
additive can be applied to the smooth surfaces 428 to increase
hydrophobicity of the smooth sections 428, thereby further
accelerating condensation. In some cases, a laminating mold process
can be used to incorporate a section of hydrophobic and smooth
surface to induce and accelerate the condensation. In some cases, a
coating, such as wax or any other hydrophobic material, can be
applied to the smooth sections 428 to induce faster condensation
and form water droplets.
[0136] The food containers and components thereof of FIGS. 22A,
22B, 23, and 24 are designed and configured to maximize the
retained heat and temperature of a food item stored therein, while
maximizing the crispiness of the food item by minimizing the
moisture reabsorption by the food item and redirecting moisture and
condensed water away from the food item.
[0137] Referring now to FIGS. 27-41, various views of a food
container 500 and its base portion 502 and cover portion 504 are
shown. The food container 500 may be similar or identical to the
food containers 100, 200, and 300 in many respects (e.g., shapes,
materials, sizes, features). Accordingly, at least some of the
discussion above is applicable to the food container 500 and may
not be repeated below for the sake of brevity. As examples, the
cover portion 504 has structures similar to the other cover
portions described herein, and can include any of the features of
the other cover portions described herein to the extent they are
not incompatible with the features described herein for the food
container 500. Further, the features described herein for the cover
portion 504 can be incorporated into any of the other cover
portions described herein to the extent they are not incompatible
with the features of such other cover portions. The base portion
502 has structures similar to the other base portions described
herein, and can include any of the features of the other base
portions described herein to the extent they are not incompatible
with the features described herein for the food container 500.
Further, the features described herein for the base portion 502 can
be incorporated into any of the other base portions described
herein to the extent they are not incompatible with the features of
such other base portions.
[0138] FIGS. 27-31 illustrate top perspective, bottom perspective,
top, bottom, and side views, respectively, of the base portion 502.
As illustrated in FIGS. 27-31, the base portion 502 includes an
upwardly facing circular-shaped food receiving portion 508 which
receives a pizza thereon. The base portion 502 further includes a
raised peripheral rim 510 disposed about a perimeter of the food
receiving portion 508. The rim 510 comprises a raised, upwardly
facing apex surface 512 and an downwardly and outwardly facing
sidewall 514 which meets with a substantially planar base flange
516 that extends outwardly from the rim 510. The rim 510 improves
the rigidity of the base portion 502, such as by interrupting
bending of the base portion 502 along a diameter of the base
portion 502. The rim 510 also prevents food items held on the food
receiving portion 508 of the base portion 502 from sliding off the
food receiving portion 508 of the base portion 502.
[0139] The outwardly facing sidewall 514 of the raised rim 510 of
the base 502 includes eight cover interface portions 532 spaced
45.degree. apart from each other, each of which is positioned
equidistantly between an adjacent pair of cutting notches 518,
which are described further below. The cover interface portions 532
extend radially outward from the remainder of the outward facing
sidewall 514. The cover interface portions 532 of the base 502 can
engage an inwardly and downwardly facing peripheral rim 526 of the
cover 504 when the cover 504 is engaged with the base 502 to
provide a friction fit, press fit, or interference fit between the
cover 504 and the base 502, which retains the cover 504 on the base
502 until removed by a user.
[0140] The food receiving portion 508 of the base portion 502
includes a planar surface and a number of features which extend at
least one of upward or downward from the planar surface. In
particular, the food receiving portion 508 includes a central well
520 which extends downwardly from the planar surface and receives
liquid drippings or condensation from the cooked food (e.g., pizza)
placed in the food container 500. At a center of the central well
520, the food receiving portion 508 also includes a protrusion 506
that extends upward relative to the bottom of the central well 520
to an elevation substantially corresponding to an elevation of
bottom ends of channels 522 formed in the food receiving portion
508, as described further below. The protrusion 506 at the center
of the central well 520 improves the rigidity of the base portion
502, such as by interrupting bending of the base portion 502 along
a line defined by two of the channels 522.
[0141] The food receiving portion 508 also includes a plurality of
food receiving portion channels or grooves 522 extending downwardly
below the planar surface and running radially outward from the
central well 520 and terminating at the raised peripheral rim 510.
Each pair of adjacent channels 522 and a corresponding portion of
the raised peripheral rim 510 delineate a respective sector portion
of the food receiving portion 508 which supports a portion of a
food item (e.g., an individual slice of pizza). In the illustrated
implementation, the base 502 includes eight channels 522 and eight
sector portions.
[0142] The plurality of channels 522 are equally radially spaced to
enable cutting of the food item (e.g., pizza) into equally sized
pieces when a cutting tool (e.g., knife) moves along the channels.
Since the channels 522 extended downward from the planar surface of
the food receiving portion 508, a user may cut through the food
item over the channels without damaging (e.g., cutting) the food
receiving portion 508 of the base 502. The channels 522 serve as
guides for a cutting tool to cut eight equally sized pieces of a
food item (e.g., pizza). As illustrated in FIGS. 27-31, the raised
peripheral rim 510 includes a plurality of cutting notches 518
where a notch is formed in the raised upwardly facing apex surface
512 of the rim 510. Each of the cutting notches 518 is located at a
circumferential position about the central well 520 corresponding
to or matching a circumferential position of a respective one of
the grooves 522 about the central well 520.
[0143] Thus, when a knife, blade, wheeled pizza cutter, or other
cutting tool used to cut a pizza received on the food receiving
portion 508 reaches an outer peripheral end of one of the grooves
522, the blade or other tool can also be received within a
respective one of the cutting notches 518. A portion of the rim 510
below or underneath each of the cutting notches 518 can be thicker
than other portions of the rim 510, to provide additional support
to the cutting notches 518 so they are less likely to collapse when
contacted by a cutting instrument.
[0144] Each sector portion of the food receiving portion 508
includes a sector well 528 which may receive liquid drippings from
the food product therein. Each sector portion also includes a
plurality of outer, distal, or peripheral raised sector ribs or
projections 530 which extend upward from the planar surface of the
food receiving portion 508 having respective uppermost portions
that support the hot food product (e.g., pizza). In the illustrated
implementation, each of the ribs 530 is located between a
respective sector well 528 and the portion of the rim 510 bounding
the respective sector portion of the food receiving portion 508.
Also in the illustrated implementation, shapes of the ribs 530 are
elongated and have a length dimension which extends radially with
respect to the central well 520. In alternative implementations,
the ribs 530 may be sunken or recessed to form groves rather than
ridges, and/or the shapes of the ribs 530 may be elongated and
circumferential with respect to the central well 520.
[0145] Each sector portion also includes a plurality of inner,
proximal, or central raised sector ribs or projections 524 which
extend upward from the planar surface of the food receiving portion
508 having respective uppermost portions that support the hot food
product (e.g., pizza). In the illustrated implementation, each of
the ribs 524 is located between a respective sector well 528 and
the central well 520 at the center of the food receiving portion
508. Also in the illustrated implementation, shapes of the ribs 524
are elongated and have a circumferential length dimension which
extends circumferentially with respect to the central well 520,
such that the ribs 524 within a single sector portion are
concentric with one another. Including the circumferential ribs 524
can improve or increase the rigidity of the base portion 502, such
as by interrupting bending of the base portion 502 along a diameter
of the base portion 522. In alternative implementations, the ribs
524 may be sunken or recessed to form groves rather than ridges,
and/or the shapes of the ribs 524 may be elongated and radial with
respect to the central well 520.
[0146] FIGS. 32-36 illustrate top perspective, bottom perspective,
top, bottom, and side views, respectively, of the cover portion
504. As illustrated in FIGS. 32-36, the cover 504 includes a
central dome portion 536 having a raised outer rim 542 spaced
radially outward from the center of the dome portion 536, a
vertical sidewall 538 that extends downward from, and at a
90.degree. angle with respect to, the raised outer rim 542, and a
flat, substantially planar, horizontal ceiling portion 544 that
extends radially inward from, and at a 90.degree. angle with
respect to, the vertical sidewall 538. An overall height of the
cover portion 504 can be at least 2 inches, at least 21/4 inches,
at least 21/2 inches, at least 23/4 inches, or at least 3
inches.
[0147] As also shown in FIGS. 32-36, the cover 504 includes a
peripheral rim 526 located at an outer peripheral end and at a
bottom end thereof. The peripheral rim 526 includes a plurality of
radially outwardly extending protrusions 534, wherein an inner
surface of each of the protrusions 534 is sized and dimensioned to
receive, accommodate, or mate with an outer surface of a respective
one of the relatively thick portions of the rim 510 of the base
portion 502 underneath a respective one of the cutting notches 518.
The protrusions 534 can be referred to as "indexing bumps" and can
assist a user in aligning the cover portion 504 with the base
portion 502 and locking the cover portion 504 to the base portion
502.
[0148] The peripheral rim 526 forms, bounds, and defines an
inwardly and downwardly facing perimeter channel sized and
dimensioned to engage the raised perimeter rim 510 of the base 502
when the cover 504 is engaged with the base 502. When the cover 504
is engaged with the base 502, the peripheral rim 526 contacts the
top surface 512 and sidewall 514, including the cover interface
portions 532 thereof, of the raised rim 510 of the base 502 to form
a seal which may limit or even prevent the flow of air into or out
of an enclosed chamber formed within the food container 500 to
house the food item therein. In some implementations, the
peripheral rim 526 and the raised rim 510, including the sidewall
514 and cover interface portions 532 thereof, are sized and
dimension to form a snug fit, interference fit, press fit, or
friction fit therebetween when the cover 504 is engaged with the
base 502, thereby generating a frictional force which holds the
cover 504 in a closed configuration on the base 502. Such
frictional fastening force can resist external forces applied to
the container 500 so that the container 500 remains closed
throughout storage, transportation or any other function of the
container 500.
[0149] FIGS. 37-41 illustrate top perspective, bottom perspective,
top, bottom, and side views, respectively, of the food container
500 including both the base portion 502 and the cover portion 504,
wherein the base portion 502 is snugly coupled to the cover portion
504.
[0150] To the extent that they are not inconsistent with the
specific teachings and definitions herein, all of the US patents,
US patent application publications, US patent applications,
referred to in this specification and/or listed in the Application
Data Sheet, including but not limited to U.S. Patent Application
Ser. No. 62/311,787, filed Mar. 22, 2016, U.S. Patent Application
Ser. No. 62/651,633, filed Apr. 2, 2018, U.S. Patent Application
Ser. No. 62/667,179, filed May 4, 2018, and U.S. Patent Application
Ser. No. 62/697,029, filed Jul. 12, 2018, are hereby incorporated
herein by reference in their entirety.
[0151] The various implementations described above can be combined
to provide further implementations. These and other changes can be
made to the implementations in light of the above-detailed
description. In general, in the following claims, the terms used
should not be construed to limit the claims to the specific
implementations disclosed in the specification and the claims, but
should be construed to include all possible implementations along
with the full scope of equivalents to which such claims are
entitled. Accordingly, the claims are not limited by the
disclosure.
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